Ultrasonic inspection is widely used for non-destructive evaluation of composite adhesive joints. However, there are serious challenges in applying ultrasonic testing on metal to composite hybrid joints, because they are multi-layered, made out of dissimilar materials and relatively thin. The ultrasonic signals reflected by different layers are overlapped, scattered and attenuated. The aim of this research was to develop an ultrasonic inspection technique suitable for defect detection in hybrid metal to composite joints where the metal part has pin arrays, which entangle with the composite part. The immersion pulse echo technique was used to collect data. In order to overcome the problems related to the rough surface and non-parallel layers a novel signal post-processing algorithm for reconstruction of the joint area was developed and validated experimentally. It is shown that using the proposed technique the positions of different defects can be determined.
